Baking & Snack - February 2020 - 48

KWIK TRIP

MIDWEST WORK ETHIC AND
PRIDE IN A JOB WELL DONE
If Kwik Trip's new 200,000-sq-ft baking facility were a vehicle, it might
still have that "new car smell," even
a year after starting up the lines.
That's because every coworker in
the plant takes a great amount of
pride in the new operation. Kwik Trip
invested in several technology upgrades that were new to the bakery.
Each upgrade was met with open
arms by coworkers at every level.
"The coworkers are the reason
this plant looks and runs the way
it does," said Eric Fonstad, Kwik
Trip director of operations for the
bread and bun bakery. "They're the
ones doing the work every day. The
technology in this plant is highly
automated, and the coworkers have
done a tremendous job in adapting
to all the changes."
And they work hard to care for
what they've been given. Call it a
company culture being driven from
the top, or call it that good oldfashioned Midwest work ethic. "Our
owner, Don Zietlow, expects an
honest, hard day's work out of you.
But he's going to reward you for
that, too. And that's how it should
be," Mr. Fonstad said.
That pride in a job well done can
be seen in any given moment on
the plant floor. Here, there's no such
thing as downtime. If product is not
moving on the line, coworkers are
meticulously running a cloth down
the machines, keeping everything
looking clean and pristine at all
times.
"I've said it before, and I'll say it
again: The coworkers deserve the
credit for making this plant work,"
Mr. Fonstad proclaimed. "We as
leaders can give them guidance, but
at the end of the day, the coworkers
need to execute the plan, and they
do it very well ... every day."

48 Baking & Snack February 2020 / www.bakingbusiness.com

we were first introduced to continuous,
we needed some education," Mr. Fonstad
said. "We spent a lot of time learning
how to run it. They had a lot of in-house
supervision for us and trained us on
how to use the mixer as far as moisture
content and mix time. We developed all
our recipes with Reading, and they did a
great job with us."
The mixer feeds two AMF Accupan
bun systems that produce 1,600 buns a
minute. Each divider makes and deposits
them into a Bundy Baking Solutions pan.
The pans are fed into the makeup area by
a Workhorse Automation system.
"We run all our bun products at full
rate," Mr. Fonstad said. "None of them
are at half or even three-quarter rate.
We're running them at the full rate the
system was designed to run."
With the three new lines and the efficiency of the continuous mixer, Kwik
Trip makes more bread and buns in one
shift per day - instead of two at the old
plant - and creates a better work-life
balance for coworkers. "Now, they work
four 10-hour shifts," Mr. Fonstad said.
"We eliminated overtime, which is a
big benefit."
Going bigger, better and faster is all
about doing more with less.

Dialing it in
Front to back, it takes roughly 2.5 hours to
create a loaf of Kwik Trip bread or pack of
buns. And it took a lot of dialing in to perfect every minute of that process for the

Kwik Trip supplies bread loaves for retail and foodservice
at its more than 700 c-stores.
19 total SKUs produced in the new plant.
The control centers on AMF's AllenBradley touchscreen HMI for each side
allow operators to see the progress of each
operation and easily tweak as needed,
whether in the AMF proof box, BakeTech
oven or AMF cooling tower.
A Burford Corp. seeder/splitter on each
side executes splits for Kwik Trip's submarine buns and French rolls on the bun side
and tops the 8-grain bread before baking
on the bread side.
After bread and buns are removed via
Capway depanners and the bun pans head
through a Henry Group cleaning system,
an EyePro System ensures that products
are in spec and kicks rejected product off
the line. This also allows operators to make
any adjustments to the bake.
In addition to quality control, food
safety is of the utmost importance,
which is why both sides include Fortress
Technologies metal detection at three
points in the process: makeup, post bake
and packaging.
Perhaps the most critical aspect the bakery needed to dial in was packaging. When
the technology upstream is kicking out
that much product that fast, there's risk of
bottlenecks at the end of the line. To avoid
this, Kwik Trip placed a heavy emphasis on
how it set up the packaging department,
which includes five AMF bread slicers, five
UBE baggers each for bread and buns, two


http://www.bakingbusiness.com

Baking & Snack - February 2020

Table of Contents for the Digital Edition of Baking & Snack - February 2020

Baking & Snack - February 2020
Contents
Editorial - What can bread learn from the little black dress?
Newsfront
People/In Brief
2020 Baking Hall of Fame - The history makers
2020 BAKING HALL OF FAME - The teacher
2020 BAKING HALL OF FAME - The engineer
2020 BAKING HALL OF FAME - The architect
2020 BAKING HALL OF FAME - The helper
Industry Confi dence Survey - Weathering the storm
Kwik Trip - Land of opportunity
Donuts - A hole in one
Health and wellness - Impacting consumer health
Protein - Blend for balance
Probiotics - Good for the gut
Snack processing - Story of the decade
Pan glazing - Life in the fast lane
Depositing - Bull's-eye
Production management - ERP software 101
Trays & baskets - Stacked for food safety
Meeting preview: ABA - A gold mine of information
Events
Innovations - Contents
Featured innovation center
Ingredients & formulating
Equipment & packaging
Patents
New on the shelf
Marketplace
Ad index
New product spotlight
Baking & Snack - February 2020 - Baking & Snack - February 2020
Baking & Snack - February 2020 - Baking & Snack - February 2020
Baking & Snack - February 2020 - 2
Baking & Snack - February 2020 - 3
Baking & Snack - February 2020 - 4
Baking & Snack - February 2020 - 5
Baking & Snack - February 2020 - 6
Baking & Snack - February 2020 - Contents
Baking & Snack - February 2020 - 8
Baking & Snack - February 2020 - 9
Baking & Snack - February 2020 - Editorial - What can bread learn from the little black dress?
Baking & Snack - February 2020 - 11
Baking & Snack - February 2020 - 12
Baking & Snack - February 2020 - 13
Baking & Snack - February 2020 - Newsfront
Baking & Snack - February 2020 - 15
Baking & Snack - February 2020 - People/In Brief
Baking & Snack - February 2020 - 17
Baking & Snack - February 2020 - 18
Baking & Snack - February 2020 - 19
Baking & Snack - February 2020 - 20
Baking & Snack - February 2020 - 2020 Baking Hall of Fame - The history makers
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The teacher
Baking & Snack - February 2020 - 23
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The engineer
Baking & Snack - February 2020 - 25
Baking & Snack - February 2020 - 26
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The architect
Baking & Snack - February 2020 - 28
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The helper
Baking & Snack - February 2020 - 30
Baking & Snack - February 2020 - Industry Confi dence Survey - Weathering the storm
Baking & Snack - February 2020 - 32
Baking & Snack - February 2020 - 33
Baking & Snack - February 2020 - 34
Baking & Snack - February 2020 - 35
Baking & Snack - February 2020 - 36
Baking & Snack - February 2020 - 37
Baking & Snack - February 2020 - Kwik Trip - Land of opportunity
Baking & Snack - February 2020 - 39
Baking & Snack - February 2020 - 41
Baking & Snack - February 2020 - 40
Baking & Snack - February 2020 - 42
Baking & Snack - February 2020 - 43
Baking & Snack - February 2020 - 44
Baking & Snack - February 2020 - 45
Baking & Snack - February 2020 - 46
Baking & Snack - February 2020 - 47
Baking & Snack - February 2020 - 48
Baking & Snack - February 2020 - 49
Baking & Snack - February 2020 - 50
Baking & Snack - February 2020 - 51
Baking & Snack - February 2020 - 52
Baking & Snack - February 2020 - 53
Baking & Snack - February 2020 - Donuts - A hole in one
Baking & Snack - February 2020 - 55
Baking & Snack - February 2020 - 56
Baking & Snack - February 2020 - 57
Baking & Snack - February 2020 - 58
Baking & Snack - February 2020 - 59
Baking & Snack - February 2020 - 60
Baking & Snack - February 2020 - 61
Baking & Snack - February 2020 - 62
Baking & Snack - February 2020 - 63
Baking & Snack - February 2020 - 64
Baking & Snack - February 2020 - Health and wellness - Impacting consumer health
Baking & Snack - February 2020 - 66
Baking & Snack - February 2020 - 67
Baking & Snack - February 2020 - 68
Baking & Snack - February 2020 - 69
Baking & Snack - February 2020 - 70
Baking & Snack - February 2020 - Protein - Blend for balance
Baking & Snack - February 2020 - 72
Baking & Snack - February 2020 - 73
Baking & Snack - February 2020 - 74
Baking & Snack - February 2020 - 75
Baking & Snack - February 2020 - 76
Baking & Snack - February 2020 - 77
Baking & Snack - February 2020 - 78
Baking & Snack - February 2020 - 79
Baking & Snack - February 2020 - 80
Baking & Snack - February 2020 - Probiotics - Good for the gut
Baking & Snack - February 2020 - 82
Baking & Snack - February 2020 - 83
Baking & Snack - February 2020 - 84
Baking & Snack - February 2020 - 85
Baking & Snack - February 2020 - 86
Baking & Snack - February 2020 - 87
Baking & Snack - February 2020 - 88
Baking & Snack - February 2020 - Snack processing - Story of the decade
Baking & Snack - February 2020 - 90
Baking & Snack - February 2020 - 91
Baking & Snack - February 2020 - 92
Baking & Snack - February 2020 - 93
Baking & Snack - February 2020 - 94
Baking & Snack - February 2020 - 95
Baking & Snack - February 2020 - 96
Baking & Snack - February 2020 - 97
Baking & Snack - February 2020 - 98
Baking & Snack - February 2020 - Pan glazing - Life in the fast lane
Baking & Snack - February 2020 - 100
Baking & Snack - February 2020 - 101
Baking & Snack - February 2020 - 102
Baking & Snack - February 2020 - 103
Baking & Snack - February 2020 - 104
Baking & Snack - February 2020 - 105
Baking & Snack - February 2020 - 106
Baking & Snack - February 2020 - Depositing - Bull's-eye
Baking & Snack - February 2020 - 108
Baking & Snack - February 2020 - 109
Baking & Snack - February 2020 - 110
Baking & Snack - February 2020 - 111
Baking & Snack - February 2020 - 112
Baking & Snack - February 2020 - 113
Baking & Snack - February 2020 - 114
Baking & Snack - February 2020 - Production management - ERP software 101
Baking & Snack - February 2020 - 116
Baking & Snack - February 2020 - 117
Baking & Snack - February 2020 - 118
Baking & Snack - February 2020 - 119
Baking & Snack - February 2020 - 120
Baking & Snack - February 2020 - 121
Baking & Snack - February 2020 - 122
Baking & Snack - February 2020 - Trays & baskets - Stacked for food safety
Baking & Snack - February 2020 - 124
Baking & Snack - February 2020 - 125
Baking & Snack - February 2020 - 126
Baking & Snack - February 2020 - 127
Baking & Snack - February 2020 - 128
Baking & Snack - February 2020 - Meeting preview: ABA - A gold mine of information
Baking & Snack - February 2020 - Events
Baking & Snack - February 2020 - 131
Baking & Snack - February 2020 - 132
Baking & Snack - February 2020 - Innovations - Contents
Baking & Snack - February 2020 - Featured innovation center
Baking & Snack - February 2020 - 135
Baking & Snack - February 2020 - 136
Baking & Snack - February 2020 - Ingredients & formulating
Baking & Snack - February 2020 - 138
Baking & Snack - February 2020 - 139
Baking & Snack - February 2020 - Equipment & packaging
Baking & Snack - February 2020 - 141
Baking & Snack - February 2020 - 142
Baking & Snack - February 2020 - 143
Baking & Snack - February 2020 - 144
Baking & Snack - February 2020 - 145
Baking & Snack - February 2020 - 146
Baking & Snack - February 2020 - 147
Baking & Snack - February 2020 - Patents
Baking & Snack - February 2020 - 149
Baking & Snack - February 2020 - New on the shelf
Baking & Snack - February 2020 - 151
Baking & Snack - February 2020 - Marketplace
Baking & Snack - February 2020 - 153
Baking & Snack - February 2020 - 154
Baking & Snack - February 2020 - 155
Baking & Snack - February 2020 - 156
Baking & Snack - February 2020 - 157
Baking & Snack - February 2020 - 158
Baking & Snack - February 2020 - 159
Baking & Snack - February 2020 - 160
Baking & Snack - February 2020 - Ad index
Baking & Snack - February 2020 - New product spotlight
Baking & Snack - February 2020 - 163
Baking & Snack - February 2020 - 164
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http://digitalbs.bakingbusiness.com/sosland/bs/2004_02_01
http://digitalbs.bakingbusiness.com/sosland/bs/2003_12_01
http://digitalbs.bakingbusiness.com/sosland/bs/2003_11_01
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